Indoor unit for air conditioner

ABSTRACT

Provided is an indoor unit, for an air conditioner, including a light-weight air guiding plate whose attachment has high strength. The indoor unit, for an air conditioner, includes: an air guiding plate provided to an indoor-unit body of the indoor unit, and opens and closes an outlet of air and guides the air blown out from the outlet; and an attachment for attaching the air guiding plate to the indoor-unit body. The air guiding plate is formed of foam resin. The attachment is formed of non-foam resin.

TECHNICAL FIELD

The present invention relates to an indoor unit, for an air conditioner, including an air guiding plate.

TECHNICAL FIELD

A conventional indoor unit for an air conditioner (hereinafter simply referred to as “air-conditioning indoor unit”) is provided with an air guiding plate typically called “blade component” in the front of the air-conditioning indoor unit. The air guiding plate is capable of opening and closing an air outlet of the air-conditioning indoor unit. When the outlet is open, the air guiding plate is capable of adjusting the direction of the air to be blown out from the outlet.

Patent Document 1 discloses an air conditioner including an air guiding plate formed of a plate-like exterior material whose rear face is lined with a foam layer in which a reinforcement material is embedded

CITATION LIST [Patent Document]

[Patent Document 1] Japanese Unexamined Patent Application Publication No. 2008-134010 (published on Jun. 12, 2008).

SUMMARY OF INVENTION Technical Problem

A typical air guiding plate includes an attachment for attaching the air guiding plate to the body of an air-conditioning indoor unit. The attachment usually has a recess where a protruding member provided to the body of the air-conditioning indoor unit is inserted and engages.

Non-foam resin has sufficient strength as a material of the attachment. Hence, even if the attachment provided is shaped into a recess, the non-foam resin ensures sufficient strength as the attachment. However, foam resin is lower in strength as the material than non-foam resin. Hence, when an attachment shaped into a recess is provided to the air guiding plate lined with the foam layer disclosed in Patent Document 1, the strength of the attachment might be insufficient.

An aspect of the present invention is intended to provide an indoor unit, for an air conditioner, including a light-weight air guiding, plate whose attachment has high strength.

Solution to Problem

In order to solve the above problem, an indoor unit, for an air conditioner, according to an aspect of the present invention includes an air guiding plate provided to an indoor-unit body of the indoor unit, and opens and closes an outlet of air and guides the air blown out from the outlet, wherein the air guiding plate is formed of foam resin, the indoor unit includes an attachment for attaching the air guiding plate to the indoor-unit body, and the attachment is formed of non-foam resin, and has at least a portion embedded in the air guiding plate.

Advantageous Effects of Invention

An aspect of the present invention makes it possible to provide an indoor unit, for an air conditioner, including a light-weight air guiding plate whose attachment has high strength.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view illustrating an appearance of an air-conditioning indoor unit of a first embodiment.

FIG. 2 (a) is a side view illustrating a condition of an air guiding plate when the air-conditioning indoor unit in FIG. 1 is OFF. FIG. 2 (b) is a side view illustrating a condition of the air guiding plate when the air-conditioning indoor unit in FIG. 1 is in cooling. FIG. 2 (c) is a side view illustrating a condition of the air guiding plate when the air-conditioning indoor unit in FIG. 1 is in heating.

FIG. 3 is a cross-sectional view along a width of the air guiding plate in FIG. 1.

FIG. 4 is a plan view illustrating an example of a shape of the air guiding plate.

FIGS. 5 (a) to (c) are drawings to sequentially explain how to attach the air guiding plate to an indoor-unit body.

FIG. 6 is a side view illustrating a shape of a catcher.

FIG. 7 is a cross-sectional view along a width of an air guiding plate according to a second embodiment.

FIG. 8 is a drawing schematically illustrating an indoor-unit body to which the air guiding plate according to the second embodiment is attached.

DESCRIPTION OF EMBODIMENTS First Embodiment

Described below are embodiments of the present invention, with reference to the drawings. FIG. 1 is a perspective view illustrating an appearance of an indoor unit 1 for an air-conditioning indoor unit according to this embodiment.

(Outline of Air-Conditioning Indoor Unit 1)

As illustrated in FIG. 1, the indoor unit 1 for an air conditioner (hereinafter simply referred to as “air-conditioning indoor unit 1”) includes an air guiding plate 3 in front of an indoor-unit body 2. The indoor-unit body 2 has, for example, an inlet 11 in an upper portion thereof, an outlet 12 in a lower front portion thereof, and a not-shown air-blowing fan and a not-shown heat exchanger therein. The air-conditioning indoor unit 1 is capable of, for example, cooling, heating, dehumidifying, and air-blowing. Hence, the air-conditioning indoor unit 1 sucks air from the inlet 11, conditions the sucked air therein in accordance with an operation set by a user, and blows the conditioned air from the outlet 12 (see FIG. 2).

FIG. 2 (a) is a side view illustrating a condition of the air guiding plate 3 when the air-conditioning indoor unit 1 is OFF, FIG. 2 (b) is a side view illustrating a condition of the air guiding plate 3 when the air-conditioning indoor unit 1 is in cooling. FIG. 2 (c) is a side view illustrating a condition of the air guiding plate 3 when the air-conditioning indoor unit 1 is in heating.

As illustrated in FIGS. 1 and 2, the air guiding plate 3 is shaped into a plate having a gently curved portion between upper and lower edges of the plate. When positioned to close the outlet 12, the air guiding plate 3 is curved to be concave in front view, and to be convex toward the indoor-unit body 2. A width (horizontal) dimension of the air guiding plate 3 is greater than a dimension of a front face of the indoor-unit body A vertical (upper-lower) dimension of the air guiding plate 3 (the dimension along the flow of the air) is significantly greater than a dimension of the outlet 12, and is approximately as great as a vertical (upper-lower) dimension of the front face of the indoor-unit body 2.

The air guiding plate 3 is driven by, for example, a conventionally known driving mechanism (not shown) having two arms each provided on the left and the right of the driving mechanism to support the air guiding plate 3. When the indoor-unit body 2 is OFF, the air guiding plate 3 closes the outlet 12 as illustrated in FIG. 2 (a). When the air-conditioning indoor unit 1 is in cooling, the air guiding plate 3 in the condition illustrated in FIG. 2 (a) moves, so that an upper portion of the air guiding plate 3 slightly opens as seen in a condition illustrated in FIG. 2 (b). Moreover, when the air-conditioning indoor unit 1 is in heating, the air guiding plate 3 in the condition illustrated in FIG. 2 (a) moves, so that a lower portion of the air guiding plate 3 widely opens as seen in a condition illustrated in FIG. 2 (c).

Note that the air guiding plate 3 may have opposing vertical ends removably supported at multiple portions along the width, and may be driven by a driving mechanism having an arm in the vertically substantial middle.

(Structure of Air Guiding Plate 3)

FIG. 3 is a cross-sectional view along the width of the air guiding plate 3 in FIG. 1 in a width direction. As illustrated in FIG. 3, the air guiding plate 3 is provided with an attachment 32 (a protrusion). Moreover, the air guiding plate 3 includes a coating layer 33 coating a surface of the air guiding plate 3. Note that FIG. 3 only illustrates a cross-section of a portion near an end of the air guiding plate 3. The air guiding plate 3 opens and closes the outlet 12, and guides the air flown out from the outlet 12.

The air guiding plate 3 is formed of foam resin. A recently developed foam resin is higher in strength than conventional foam resists (e.g., polystyrene foam). Preferably, such a foam resin may be used as a material of the air guiding plate 3. Specifically, the foam resin to form the air guiding plate 3 may be mainly made of, for example, modified polyphenylene ether resin. The air guiding plate 3 may be shaped into a plate having a thickness ranging from 2 to 3 cm and a width of approximately 180 cm.

The attachment 32 is a member for attaching the air guiding plate 3 to the indoor-unit body 2. The attachment 32 is shaped into a protrusion to be inserted in a recess of the indoor-unit body 2 to be described later. More specifically, the attachment 32 includes: a trunk 32 a extending perpendicularly to the width of the air guiding plate 3; and a branch 32 b extending from the trunk 32 a in parallel with the width of the air guiding plate 3.

The attachment 32 is formed of non-foam resin. A specific example of the non-foam resin to form the attachment 32 includes acrylonitrile butadiene styrene (ABS) or high impact poly styrene (HI-PS). As illustrated in FIG. 3, the attachment 32 has a portion embedded in the air guiding plate 3. Preferably, a plurality of attachment 32 may be provided to the air guiding plate 3 along the width of the air guiding plate 3.

An example of the coating layer 33 is shaped into a thin sheet having a thickness approximately ranging from 0.1 to 1 mm, and is formed of such a resin as ABS, poly propylene (PP), poly ethylene terephthalate (PET), or poly ethylene (PE). The coating layer 33 is provided to coat the substantially entire air guiding plate 3. Note that the coating layer 33 is kept from coating the attachment 32.

The coating layer 33 is formed of non-foam resin higher in strength than, the air guiding plate 3. Hence, the air guiding plate 3 including the coating layer 33 improves in strength compared with the air guiding plate 3 without the coating layer 33. Depending of the degree of the improvement in strength of the air guiding plate 3 due to the coating layer 33 included, the air guiding plate 3 may be formed thinner than the one exemplified above.

Moreover, when the air guiding plate 3 does not include the coating layer 33, the appearance of the air guiding plate 3 is inevitably poor because the surface of the air guiding plate 3 is noticeably uneven. When the surface of the coating layer 33 is smooth, the air guiding plate 3 including the coating layer 33 improves in appearance compared with the one without the coating layer 33. Note that the air guiding plate 3 does not necessarily include the coating layer 33.

(How to Attach Air Guiding Plate 3)

Described below is how to attach the air guiding plate 3 to the indoor-unit body 2.

FIG. 4 is a plan view illustrating an example of a shape of the air guiding plate 3. In the example illustrated in. FIG. 4, the attachment 32 includes three attachments; namely, an attachment 321, an attachment 322, and an attachment 323, In the description below, the attachments 321, 322, and 323 are sequentially aligned in the stated order from the right along the width of the air guiding plate 3.

The attachments 321, 322, and 323 respectively include trunks 321 a, 322 a, and 323 a and branches 321 b, 322 b, and 323 b. The branch 321 b extends right in relation to the trunk 321 a. The branches 322 b and 323 b extend left in relation to the trunks 322 a or 323 a.

The attachments 321 and 322 are secured to the air guiding plate 3. Meanwhile, the attachment 323 includes a sliding mechanism 323 c to move the attachment 323 in parallel with the width of the air guiding plate 3 in relation to the air guiding plate 3. In the description below, as to positions of the attachment 323, a position in which the attachment 323 engages with the indoor-unit body 2 is referred to as an engagement position, and a position in which the attachment 323 does not engage with the indoor-unit body 2 is referred to as a non-engagement position. In the example illustrated in FIG. 4, the engagement position is to the left of the non-engagement position.

FIGS. (a) to (c) are drawings to sequentially explain how to attach the air guiding plate 3 to the indoor-unit body 2. The branches 321 b, 322 b, and 323 b are respectively inserted in catchers (recesses) 21, 22, and 23 provided to the indoor-unit body 2, so that the attachments 321, 322, and 323 respectively engage with the catchers 21, 22, and 23. The catchers 21, 22, and 23 are aligned from the right in the stated order along the width of the indoor-unit body 2. Moreover, the catchers 21, 22, and 23 are provided to a distal end of an arm of the conventionally known driving mechanism as described above.

Note that, in FIGS. (a) to (c), for the sake of simplicity, the catchers 21, 22, and 23 are arranged in a line in parallel with the width of the indoor-unit body 2. Furthermore, the attachments 321, 322, and 323 are arranged to correspond to the positions of the catchers 21, 22, and 23. However, the positions of the catchers 21, 22, and 23 and the attachments 321, 322, and 323 are not limited to the examples illustrated in FIGS. 5 (a) to (c).

The catcher 21 has an opening to the left in the width of the indoor-unit body 2. Hence, the branch 321 b is inserted in the catcher 21 from the left in the width of the indoor-unit body 2. Meanwhile, the catcher 23 has an opening to the right in the width of the indoor-unit body 2. Hence, the branch 323 b is inserted in the catcher 23 from the right in the width of the indoor-unit body 2.

FIG. 6 is a side view illustrating a shape of the catcher 22. As illustrated in FIG. 6, the catcher 22 is shaped into a substantial C-shape. Thus, when the attachment 322 is inserted in the catcher 22, the branch 322 b is moved perpendicularly to the width of the indoor-unit body 2 and inserted from the opening of the substantial C-shape of the catcher 22.

When the air guiding plate 3 is attached to the indoor-unit body 2, the attachment 323 is previously moved to the non-engagement position. As illustrated in FIG. 5 (a), while the width of air guiding plate 3 is angled in relation to the width of the indoor-unit body 2, the air guiding plate 3 is moved right along the width of the indoor-unit body 2. Hence, the branch 321 b is inserted in the catcher 21. Next, as illustrated in FIG. 5 (b), the width of the indoor-unit body 2 and the width of the air guiding plate 3 are positioned in parallel with each other, such that the branch 322 b moves substantially perpendicularly to the width of the indoor-unit body 2, and is inserted in the catcher 22.

When the branch 322 b is inserted in the catcher 22, the 323 b is to be positioned to be inserted into the catcher 23 if the attachment 323 is in the engagement position. Hence, as illustrated in FIG. 5 (c), the attachment 323 is moved from the non-engagement position to the engagement position; that is, the attachment 323 is moved left along the width of the indoor-unit body 2, so that the branch 323 b is inserted in the catcher 23. In the above sequence, the air guiding plate 3 is attached to the indoor-unit body 2.

When a conventional air guiding plate is attached to the indoor-unit body, the air guiding plate per se is bent. However, even though intended to be bent, the air guiding plate 3 formed of foam resin might not be bent but be broken. In the above method, the air guiding plate 3 does not have to be bent, reducing the risk of damage to the air guiding plate 3 when the air guiding plate 3 is attached to the indoor-unit body 2.

Note that, in the above example, the attachment 323 can be moved in parallel with the width of the air guiding plate 3. Meanwhile, the catcher 23 is secured to the indoor-unit body 2. However, in an aspect of the present disclosure, the attachment 323 may be secured to the air guiding plate 3, and the catcher 23 may be movable in parallel with the width of the indoor-unit body 2. Alternatively, both the attachment 323 and the catcher 23 may be movable in parallel with each other.

Moreover, the directions in which the branches 321 b, 322 b, and 323 b extend, and the shapes of the catchers 21 to 23 shall not be limited to the above examples. Furthermore, the shapes per se of the attachments 321 to 323 shall not be limited to those including the trunks 321 a, 322 a, and 323 a and the branches 321 b, 322 b, and 323 b. In addition, the number of the attachments and the catchers included in the air-conditioning indoor unit according to an aspect of the present disclosure shall not be limited to the above numbers.

(How to Manufacture Air Guiding Plate 3)

Described below is how to manufacture the air guiding plate 3.

The air guiding plate 3 is formed integrally with the attachment 32. Specifically, the air guiding plate 3 is formed integrally with the attachment 32 by, for example, insert molding. More specifically, while the attachment 32 previously formed by, for example, injection molding is inserted in a mold for forming the air guiding plate 3, foam-resin beads as a raw material of the air guiding plate 3 are injected into the mold. Then, the mold is heated and cooled so that the air guiding plate 3 and the attachment 32 are formed. Thus, the above features eliminate the need of a step of joining the air guiding plate 3 and the attachment 32 together using, for example, adhesive after the formation of the air guiding plate 3. In addition, the presence or absence of the adhesive makes it possible to determine whether the air guiding plate 3 and the attachment 32 are integrally formed together by insert molding.

Then, the air guiding plate 3 and the attachment 32 are removed from the mold, and the coating layer 33 is pasted on the surface of the air guiding plate 3. Hence, the air guiding plate 3 is finalized. Note that, instead of pasting the coating layer 33 shaped into a sheet, a solution containing a material of the coating layer 33 is applied or sprayed to the air guiding plate 3, and cured by drying or another technique. Hence, the coating layer 33 may be finalized.

As described above, the air guiding plate 3 is formed of foam resin. Such an air guiding plate 3 might not ensure sufficient strength if the air guiding plate 3 is provided with a recess as an attachment, as seen in a conventional air guiding plate formed of non-foam resin. Furthermore, the air guiding plate 3 could be formed thick in order to enhance its strength; however, such a technique might block the blow of the air.

The air guiding plate 3 of this embodiment includes the attachment 32 formed of non-foam resin and shaped into a protrusion to be inserted in a recess provided to the indoor-unit body 2. Thanks to such an attachment 32, a portion of the air guiding plate 3 to which the attachment 32 is attached is not formed thin unlike a case of forming a recess as a conventional attachment. Such a feature can reliably provide the attachment with high strength even if the attachment is formed of foam resin lower in strength as a material than non-foam resin.

Moreover, the air guiding plate 3, formed of foam resin, is higher in thermal insulation property than a conventional air guiding plate formed entirely of non-foam resin. Such a feature makes it possible to reduce condensation on the surface of the air guiding plate 3.

Second Embodiment

Described below is another embodiment of the present invention, with reference to the drawings. Note that, for the sake of explanation, identical reference signs are used to denote components with identical functions between the preceding embodiment and this embodiment. Such components will not be elaborated upon here.

FIG. 7 is a cross-sectional view along the width of an air guiding plate 3A according to this embodiment. The air guiding plate 3A is different from the air guiding plate 3 in including an attachment 34 instead of the attachment 32. The attachment 34 is formed of non-foam resin, and shaped into a recess in which protrusions 24 to 26 of an indoor-unit body 2A to be described later are inserted. Moreover, a substantial whole of the attachment 34 is embedded in the air guiding plate 3A. Note that the whole of the attachment 34 does not have to be embedded in the air guiding plate 3A. Alternatively, at least a portion of the attachment 34 may be embedded in the air guiding plate 3A.

The air guiding plate 3A substantially formed of foam resin includes a recess as an attachment. In such a configuration, the attachment might not ensure strength required for an attachment, when the protrusions 24 to 26 of the indoor-unit body 2A are inserted in, and engage with, the attachment.

However, as can be seen, the attachment 34 formed of non-foam resin can ensure high strength required for an attachment, despite a combination of a recess (a recessed shape) and foam resin lower in strength as a material than, non-foam resin.

As illustrated in, for example, FIG. 7, the attachment 34 has a groove whose cross-section is shaped into a substantial T-shape. Specifically, when the surface of the air guiding plate 3A is a top of the air guiding plate 3A in cross-section, the cross-section of the attachment 34 is shaped into a vertically inverted T-shape.

FIG. 8 is a drawing schematically illustrating the indoor-unit body 2A to which the air guiding plate 3A according to this embodiment is attached. To the indoor-unit body 2A, a conventional air guiding plate formed of non-foam resin can be attached. The indoor-unit body 2A includes, instead of the catchers 21 to 23, the protrusions 24 to 26 to be inserted in the attachment 34. The protrusions 24 to 26 are inserted in, and engage with, the attachment 34, so that the air guiding plate 3A is attached to the indoor-unit body 2A.

An indoor unit, for an air conditioner, including such an air guiding plate 3A is also included in the technical scope of the present disclosure. As to the indoor unit, for an air conditioner, including the air guiding plate 3A, the configuration of the indoor-unit body does not have to he changed from a conventional one. Note that the shapes of the attachment 34 and the protrusions 24 to 26 shall not be limited to those whose cross-section is shaped into a T-shape as described above. Any given shapes may be acceptable as long as the protrusions 24 to 26 can be inserted in, and engage with, the attachment 34.

Moreover, the air guiding plate included in the indoor unit, for an air conditioner, according to an embodiment of the present disclosure may include one or more attachments 32 and one or more attachments 34. In such a case, the indoor-unit body to which the air guiding plate is attached includes either a catcher or a protrusion whichever corresponding to the positions in which the attachments 32 and 34 included in the air guiding plate are placed.

Third Embodiment

Described below is still another embodiment of the present invention, with reference to the drawings.

A typical indoor unit for an air conditioner has an outlet of air provided with a louver defining a direction in which the air blows out. Such a louver is smaller and lighter than the air guiding plate 3 described above because the size of the louver is sufficiently large to only partially cover the outlet.

The air guiding plate included in the indoor unit for an air conditioner according to an aspect of the present disclosure may be applied to the louver.

SUMMARY

The indoor unit (1), for an air conditioner, according to a first aspect of the present invention includes an air guiding plate (31) provided to an indoor-unit body (2, 2A) of the indoor unit (1), and opens and closes an outlet (12) of air and guides the air blown out from the outlet (12), wherein the air guiding plate (31) is formed of foam resin, the indoor unit (1) includes an attachment (32, 34) for attaching the air guiding plate (31) to the indoor-unit body (2, 2A), and the attachment (32, 34) is formed of non-foam resin, and has at least a portion embedded in the air guiding plate (31).

In the above configuration, the indoor unit for an air conditioner includes an indoor-unit body and an air guiding plate. Since formed of foam resin, the air guiding plate is light. Moreover, the indoor unit for the air conditioner includes an attachment for attaching the air guiding plate to the indoor-unit body. Since formed of non-foam resin, the attachment has high strength. Furthermore, the attachment has at least a portion embedded in the air guiding plate. Through the attachment, the air guiding plate is attached to the indoor-unit body. The air guiding plate opens and closes the outlet of the air and guide the air blown out from the outlet.

Hence, the indoor unit for the air conditioner includes a light-weight air guiding plate whose attachment has high strength.

As to the indoor unit, for an air conditioner, in a second aspect of the present invention according to the first aspect, the air guiding plate may be formed integrally with the attachment by insert molding.

The above configuration eliminates the need of a step and adhesive to join the air guiding plate and the attachment together.

As to the indoor unit, for an air conditioner, in a third aspect of the present invention according to the first or second aspect, the attachment (32) may be shaped into a protrusion to be it in a recess (catchers 21, 22, 23) provided to the indoor-unit body (2).

The above configuration allows the attachment to be inserted in, and to engage with, the recess provided to the indoor-unit body, so that the air guiding plate is attached to the indoor-unit body.

As to the indoor unit, for an air conditioner, in a fourth aspect of the present invention according to the first or second aspect, the attachment (34) may be shaped into a recess in which a protrusion (24, 25, 26) provided to the indoor-unit body (2A) is inserted.

The above configuration allows the protrusion provided to the indoor-unit body, to be inserted in, and to engage with, the attachment, so that the air guiding plate is attached to the indoor-unit body.

As to the indoor unit, for an air conditioner, in a fifth aspect of the present invention according to any one of the first to fourth aspects, the air guiding plate may include a coating layer (33) coating a surface of the air guiding plate.

The above configuration makes it possible to improve the strength of the air guiding plate.

The present invention shall not be limited to the embodiments described above, and can be modified in various manners within the scope of claims. The technical aspects disclosed in different embodiments are to be appropriately combined together to implement an embodiment. Such an embodiment shall be included within the technical scope of the present invention. Moreover, the technical aspects disclosed in each embodiment are combined to achieve a new technical feature.

REFERENCE SIGNS LIST

-   1 Indoor Unit for Air Conditioner, Air-Conditioning Indoor Unit -   12 Outlet -   2, 2A Indoor-Unit Body -   21, 22, 23 Catcher (Recess) -   24, 25, 26 Protrusion -   3, 3A Air Guiding Plate -   32, 34 Attachment -   33 Coating Layer 

1. An indoor unit for an air conditioner, the indoor unit comprising an air guiding plate provided to an indoor-unit body of the indoor unit, and configured to open and close an outlet of air and guide the air blown out from the outlet, wherein the air guiding plate is formed of foam resin, the indoor unit comprises an attachment for attaching the air guiding plate to the indoor-unit body, and the attachment is formed of non-foam resin, and has at least a portion embedded in the air guiding plate.
 2. The indoor unit according to claim 1, wherein the air guiding plate is formed integrally with the attachment by insert molding.
 3. The indoor unit according to claim 1, wherein the attachment is shaped into a protrusion to be inserted in a recess provided to the indoor-unit body.
 4. The indoor unit according to claim 1, wherein the attachment is shaped into a recess in which a protrusion provided to the indoor-unit body is inserted.
 5. The indoor unit according to claim 1, wherein the air guiding plate includes a coating layer coating a surface of the air guiding plate. 